International Journal for Research in Applied Science & Engineering Technology (IJRASET)

ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887

Volume 6 Issue IV, April 2018- Available at www.ijraset.com

Design of Compound Planetary Gear Train

1
Mahesh Dobariya, 2Bhavin Gajjar
1
Student, Dept. of Mechanical Engineering, Ipcowala Institute of Engineering & Technology, Dharmaj
2
Asst. Professor, Dept. of Mechanical Engineering, Ipcowala Institute of Engineering & Technology, Dharmaj

Abstract: Planetary gear is widely used in many sectors of industries. Gears in the planetary gear trains are one of the most
critical components in which failure of one gear will affect the whole transmission system, thus it is very necessary to determine
the causes of failure to reduce it. Planetary Gear Trains have been used in Industry for their many advantages which includes
high torque/weight ratio, comparatively smaller size, improved efficiency and highly compact package. This research will
help in design calculation of compound planetary gear pair according DIN 3960 and DIN 3990 standard.
Keywords: Solid Works, DIN Standard, Kisssoft

I. INTRODUCTION
Planetary gearing is a gear system consisting of one or more outer gears, or planet gears, revolving about a central, or sun
gear. Typically, the planet gears are mounted on a movable arm or carrier, which itself may rotate relative to the sun gear. Planetary
gearing systems also incorporate the use of an outer ring gear or annulus, which meshes with the planet gears. Planetary gears are
typically classified as simple or compound planetary gears. Simple planetary gears have one sun, one ring, one carrier, and
one planet set. Compound planetary gears involve one or more of the following three types of structures: meshed-planet
(there are at least two more planets in mesh with each other in each planet train), stepped-planet (there exists a shaft
connection between two planets in each planet train), and multi-stage structures (the system contains two or more planet sets).
Compared to simple planetary gears, compound planetary gears have the advantages of larger reduction ratio, higher torque-to-
weight ratio, and more flexible configurations. The different types of failure of gears and their possible remedies are mentioned in
[1] S. Jyothirmai, [2] K. Aslantas, [3] S. H. Chang, [4] Osman Asi as bending failure (load failure), Pitting (contact stresses),
scoring and abrasive wear, in any case it is related to the loads acting on the gear. [11] Dr. Alexander Kapelevich had focused on
analysis and design of planetary gear arrangements that provide high gear ratios. A special, two-stage planetary arrangement
may use a gear ratio of over one hundred thousand to one. [12] Bernd-Robert Höhn presents planetary gear transmissions; designed
according to ISO 6336, optimized in terms of efficiency, weight and volume, and calculated using low-loss involute gears as well as
the maximum feasible number of planets.
This paper presents analysis and design of planetary gear arrangements that provide extremely high gear ratios. The real scope of
this paper is on design parameter, gear ratio, gear tooth combination, stress, and factor of safety.

II. COMPUTATIONAL METHODOLOGY

The compound planetary gear train taken from the Elecon Engineering shown in figure 2. The sun gear, planet gear, annulus are
design in SolidWokrs software. The arrangements of planetary gear train are shown in figure 1. Figures 1 present differential-
planetary arrangements with compound planet gear train. In the arrangement, the sun gear is engaged with planet 2a and planet 2a is
engaged with stationary ring gear 3a. Planet 2a and planet 2b are making compound planet gear. Planet 2b is engaged with rotating
ring gear 3b. 3b is the output gear box. There are one-stage differential-planetary arrangements that provide much higher gear
ratios. In these arrangements the output shaft is connected to the second rotating ring gear rather than the carrier, as with the
planetary gear.

Figure 1 2d arrangement of planetary gear train

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue IV, April 2018- Available at www.ijraset.com

Annulus 2

Annulus 1

Planet 2

Planet 1

Sun gear

Carrier
plate

Figure 2 Compound planetary gear train

Table 1 Specification considered for gears

Parameters Sun Planet 1 Annul-us 1 Planet 2 Annul-us 2

No. of teeth 20 46 112 40 106

Pitch dia. 65 149.5 364 130 344.5

Module 3.25 3.25 3.25 3.25 3.25

Center distance 107.2 107.25 107.25 107.25 107.25

Face width 53 53 53 55 55

Pressure angle (o) 20 20 20 20 20

Base dia. 61.08 140.49 342.04 122.16 323.74

Outside dia. 72.9 155.10 357.5 135.73 338.00

Root dia. 58.40 140.61 372.12 121.11 352.62

Generally many company used kisssoft software for gear design. Kisssoft have module to calculate gear design for only simple
planetary gear train. But in kisssoft software there is no module for calculation of compound planetary gear. Here, all calculation
are done according to DIN 3960 standard. This paper focus on geometry calculation of all gears. In this arrangement, we can
considered two stage i.e. 1-2a-3a that’s make simple planetary gear and 2b-3b that’s make compound planetary gear train. So we
can calculate data in kisssoft software for simple planetary gear train and we can compare geometry data between numerical
calculation and kisssoft software.

III. DESIGN CALCULATION

For gear mechanism, reduction ratio is ratio of no. of teeth on pinion to the no. of teeth on gear. Gear reduction mechanism reduce
the speed of driven shaft to that of driving shaft. Here, we used table method to find the reduction ration in compound planetary gear
train. In table, all value show the rpm of gear. In the table first assumption is done by fixing carrier plate and giving one rotation to
sun gear. Remaining gear speed calculated according to sun gear. Then we give unknown factor X as a speed of sun gear. Then we
added speed of carrier plate that is Y. The reduction ratio for this gear train is ratio of speed of sun gear to the speed of annulus gear.

©IJRASET (UGC Approved Journal): All Rights are Reserved 3180

 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue IV, April 2018- Available at www.ijraset.com

Table 2 reduction ratio of gear train

Rpm
Action Carrier Sun(1) Planet(2a/2b) Annulus(3a) Annulus(3b)
Z1 Z1 Z 1 Z 2b
Fixed carrier 0 1    
Z 2a Z 3a Z 2a Z 3b

Z1 X Z1 Z 1 Z 2b
Fixed carrier 0 X   X   X
Z 2a Z 3a Z 2 a Z 3b

Add y Y Y+X Y  Z1 X Y Z1 X Y  Z1  Z 2b X
Z 2a Z 3a Z2a Z 3b

Speed of Sun Gear YX

Ratio u  = Z1 Z2b or
Speed of Annulus
Y-  X
Z2a Z3b
Z 3a
1
Reduction ratio, u = Z1
Z 2 a  Z 3a
1
Z 2 a  Z 3a

112
u= 1 = 81.26
20
40  112
1
46  106

Speed of carrier:
Revolution of annulus 1 is 0. So, Y  Z 1 X =0
Z 2a

Y  Z1 X
Z 2a

X 
112
Y = 5.6Y
20
Speed of sun gear: X + Y =1800
6.6Y =1800
Y =272.72 rpm

Speed of Planet:

Np Ts

Ns Ta
20
Np =   1800
46
N p = 782.60 rpm
Speed of Annulus 2(3b):
N 3b 1
 
N s u
N 3b 1
 
1800 81 .26
N3b = 22.15 rpm

Table 4 shows calculation equation for external gear and table 5 shows calculation equation for internal gear and external gear.

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue IV, April 2018- Available at www.ijraset.com

Table 3 Calculation of gear geometry for external gear

No. Item
1 Module
2 Pressure angle
3 Number of teeth
4 Total profile shift
Symbol Formula
m -
α -
N -
x

5 Coefficient of profile shift x1, x2 -

6 Inv α tan α – α

7 Involute function Inv αw 2 tan  x1  x2  + inv α

z z 
 1 2 

8 Working pressure angle αw Find from involute function table

z1  z 2  cos  
Center distance increment 
9 y  1
factor 2  
 cos  w 
 z1  z2 
10 Center distance ax   y m
 2 
11 Pitch diameter d Zm
12 Base diameter db d cos α
db
13 Working pitch diameter dw
cos  w
(1 + y – x2) m,
14 Addendum ha1, ha2
(1 + y – x2) m
15 Whole depth h [2.25 + y – (x1 + x2)]m
16 Outside diameter da d + 2ha
17 Root diameter df da – 2h

Table 4 Calculation of gear geometry for external and internal gear

No. Item Symbol Formula
1 Module m -
2 Pressure angle α -
3 Number of teeth N -
4 Total profile shift x -

5 Coefficient of profile shift x1 , x2 -

6 Inv α Tan α – α

7 Involute function Inv αw 2 tan  x1  x 2  + inv α

z z 
 1 2 

8 Working pressure angle αw Find from involute function table

Center distance increment z1  z 2  cos  

9 y  1
factor 2  
 cos  w 
 z1  z 2 
10 Center distance ax   y m
 2 
11 Pitch diameter d Zm
12 Base diameter db d cos α
db
13 Working pitch diameter dw
cos  w
(1 + x1) m,
14 Addendum ha1, ha2
(1 – x2) m
15 Whole depth h 2.25 m
da1(Ext. gear) D1+ 2ha1
16 Outside diameter
da2(int. gear) D2 - 2ha2
df1(Ext. gear) Da1 - 2h
17 Root diameter
df2(int. gear) Da2 - 2h

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue IV, April 2018- Available at www.ijraset.com

IV. COMPARISON BETWEEN CALCULATED DATA AND KISSSOFT DATA

Here, we cannot calculate whole data for this type of compound planetary gear train in kisssoft software. But we can calculate data
for the first stage simple planetary stage in kisssoft software. Here, we have compared geometry data and various factor required for
safety between calculated data and kisssoft data. Here, we have assumed two pairs of gear combination i.e. 18-40-106 and 20-46-
112.

Table 5 Geometry data for 20-46-112

sun Planet 1 Annulus 1

parameters Kisssoft data analytical data Kisssoft data analytical data Kisssoft data analytical data

No of teeth 20 46 112

Module (mm) 3.25 3.25 3.25

Pcd (mm) 65 65 149.5 149.5 364 364

Reference center
107.25 107.25 107.25 107.25 107.25 107.25
distance
Speed (rpm) 1800 1800 782.6 782.60 0 0

Center distance based

107.62 107.56 107.62 107.56 107.62 107.56
on profile shift (mm)

Working pressure
20.45 20.45 20.45 20.45 20.45 20.45
angle
Base dia (mm) 61.08 61.08 140.48 140.49 342.04 342.04
Whole depth (mm) 7.23 7.24 7.23 7.24 7.30 7.31
Outside dia (mm) 73.19 72.9 155.22 155.1 357.5 357.5
Root dia (mm) 58.40 58.4 140.61 140.61 372.15 372.15
Contact ratio 1.58 1.6 1.58 1.95 1.9
Torque(N-mm) 360751.2 360751.2 - - 2020206.7
Tangential force(N) 3700.01 3700.01 3700.01 3700.01 3700.01 3700.012

Table 6 Geometry data for 18-40-106

Sun Planet 1 Annulus 1
analytical Kisssoft analytical analytical
parameter Kisssoft data Kisssoft data
data data data data
No of teeth 18 40 106
module 3.25 3.25 3.25
pcd 58.5 58.5 143 143 344.5 344.5
Reference center
100.75 100.75 100.75 100.75 100.75 100.75
distance
speed 1800 1800 736.36 0 0
Center distance
based on profile 101.04 101.04 101.04 101.04 101.04 101.04
shift
Working pressure
20.45 20.46 20.45 20.46 20.45 20.46
angle
Base dia 54.97 54.976 134.37 134.38 323.72 323.72
Whole depth 7.21 7.22 7.21 7.22 7.12 7.13
Outside dia 66.51 66.36 148.72 148.56 338 338
Root dia 51.90 51.90 134.11 134.11 352.62 352.62
Contact ratio 1.56 1.63 1.56/1.9 1.36/1.93 1.95 1.93
Torque(N-mm) 360751.2 360751.2 - - 2124423.7 2124423.7
Tangential force(N) 4111.12 4111.12 4111.12 4111.12 4111.12 4111.12

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue IV, April 2018- Available at www.ijraset.com

In this study, comparison of analytical value and Ansys value were considered. Calculations were done based on DIN 3960 for this
gear train. Now in order to justify the calculated data, we need to compare the analytical calculation with kisssoft data and it was
found very close.

V. CONCLUSION
In this paper, attempt has been made to find safe design and to compare calculated data through analytical approach based on DIN
3960 as well as kisssoft software.

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